Fungi growth resistant faced insulation assembly

ABSTRACT

The facing of a faced building insulation assembly includes a central field portion that is fungi growth resistant. The facing may include a fungi growth-inhibiting agent, be perforated to provide a selected water vapor permeance, and/or may include a heat activated bonding agent. The facing may have lateral tabs that are transparent, sufficiently open to enable wallboard to be directly bonded to framing members overlaid by the tabs, and/or of greater integrity than the field portion of the facing. The field portion of the facing may include a coating to stiffen the facing, inhibit fungi growth, and/or decrease flame spread and smoke formation.

BACKGROUND OF THE INVENTION

[0001] The subject invention relates to fungi growth resistant facingsfor faced building insulation assemblies, such as but not limited tothose insulation assemblies commonly used to insulate homes and otherresidential building structures; offices, stores and other commercialbuilding structures; and industrial building structures, and to thefaced building insulation assemblies faced with such facings. Thefacings of the subject invention, as applied to the insulation layers ofthe faced insulation assemblies of the subject invention, are designedto exhibit improved fungi growth-inhibiting characteristics and may alsoexhibit improved aesthetics and other improved performancecharacteristics, such as but not limited to water vapor permeance ratingdesigned for particular applications, and improved functionality toimprove installer productivity.

[0002] Building insulation assemblies currently used to insulatebuildings, especially fiberglass building insulations, are commonlyfaced with kraft paper facings, such as 30-40 lbs/3 MSF (30 to 40pounds/3000 square feet) natural kraft paper. In addition, U.S. Pat.Nos. 5,733,624; 5,746,854; 6,191,057; and 6,357,504 disclose examples ofpolymeric facings for use in faced building insulation assemblies andU.S. patent application nos. U.S. 2002/0179265 A1; U.S. 2002/0182964 A1;and U.S. 2002/0182965 A1 disclose examples of polymeric-kraft laminatesfor use in faced building insulation assemblies.

[0003] While building insulation assemblies faced with such kraft paperfacings function quite well, have been used for decades, and the patentslisted above disclose kraft paper facing materials as well asalternative facing materials, there has remained a need for facings withimproved performance characteristics. The improved facings of thesubject invention and the building insulation assemblies faced with theimproved facings of the subject invention provide faced insulationassemblies, designed to exhibit improved fungi growth-inhibitingcharacteristics, that are especially well suited for applications wherethe insulation assemblies will be subjected to hot humid conditions. Thefacings of the subject invention may also exhibit improved pest controlcharacteristics, exhibit improved performance characteristics (e.g.reduced flame spread, reduced smoke development and/or improved watervapor permeance rating), and/or enable improved installer productivityor other cost savings.

SUMMARY OF THE INVENTION

[0004] The facing of a faced building insulation assembly of the subjectinvention includes a central field portion having one or more polymericfilm layers, spunbond continuous polymeric filament mat layers;polymeric fiber mat layers, fiberglass mat layers, paper layers, paperand foil and/or scrim layers, or combinations thereof. The facing is afungi growth resistant facing as defined herein that, preferablyexhibits no more than traces of sporulating growth, non-sporulatinggrowth, or both sporulating and non-sporulating growth as defined hereinand more preferably, exhibits no sporulating growth or non-sporulatinggrowth as defined herein.

[0005] When a surface of a specimen of a facing sheet material of thesubject invention or a facing of the subject invention, as bonded to aninsulation layer of a faced insulation assembly of the subjectinvention, and a surface of a comparative specimen of a white birch orsouthern yellow pine wood, which are each approximately 0.75 by 6 inches(20 by 150 mm), are tested as follows, the specimen of facing sheetmaterial or facing of the subject invention will have less spore growththan the comparative specimen of white birch or southern yellow pine.Spore suspensions of aspergillus niger, aspergillus versicolor,penicillium funiculosum, chaetomium globosum, and asperguillus flavusare prepared that each contain 1,000,000±200,000 spores per mL asdetermined with a counting chamber. Equal volumes of each of the sporesuspensions are blended together to produce a mixed spore suspension.The 0.75 by 6 inch surface of the specimen of the facing sheet materialor facing of the subject invention and the 0.75 to 6 inch surface of thecomparative specimen of white birch or southern yellow pine wood areeach inoculated with approximately 0.50 mL of the mixed spore suspensionby spraying the surfaces with a fine mist from a chromatography atomizercapable of providing 100,000±20,000 spores/inch². The specimens areimmediately placed in an environmental chamber and maintained at atemperature of 86±4° F. (30±2° C.) and 95±4% relative humidity for aminimum period of 28 days±8 hours from the time incubation commenced(the incubation period). At the end of the incubation period, thespecimens are examined at 40× magnification. The specimen of the facingsheet material or facing of the subject invention passes the testprovided the specimen of the facing sheet material or facing has lessspore growth than the comparative specimen of white birch or southernyellow pine wood. As used in this specification and claims the term“fungi growth resistant” means the observable spore growth at a 40×magnification on the surface of the facing sheet material or facingspecimen being tested is less than the observable spore growth at a 40×magnification on either a white birch or southern yellow pinecomparative specimen when the specimens are tested as set forth in thisparagraph.

[0006] When a surface of a 50-mm by 50-mm specimen or 50-mm diameterspecimen of a facing sheet material of the subject invention or a facingof the subject invention, as bonded to an insulation layer of thesubject invention, has been tested as follows, the specimen willpreferably, exhibit only microscopically observable traces ofsporulating growth, non-sporulating growth or both sporulating andnon-sporulating growth and, more preferably, exhibit no microscopicallyobservable sporulating growth or non-sporulating growth. Separate sporesuspensions of aspergillus niger, penicillium pinophilum, chaetomiumglobosum, gliocladium virens, and aureobasidium pullulans are preparedwith a sterile nutrient-salts solution. The spore suspensions eachcontain 1,000,000±200,000 spores per mL as determined with a countingchamber. Equal volumes of each of the spore suspensions are blendedtogether to produce a mixed spore suspension. A solidifiednutrient-salts agar layer from 3 to 6 mm (⅛ to ¼ inch) is provided in asterile dish and the specimen is placed on the surface of the agar. Theentire exposed surface of the specimen is inoculated and moistened withthe mixed spore suspension by spraying the suspension from a sterilizedatomizer with 110 kPa (16 psi) of air pressure. The specimen is coveredand incubated at 28 to 30° C. (82 to 86° F.) in an atmosphere of notless than 85% relative humidity for 28 days. The surface of the specimenis then microscopically observed to visually examine for sporulatingand/or non-sporulating growth. The magnification used for making themicroscopic observations to determine both sporulating growth andnon-sporulating growth is selected to enable non-sporulating growth tobe observed. As used in this specification and claims the term “tracesof sporulating growth, non-sporulating growth, or both sporulating andnon-sporulating growth” means a microscopically observable sporulatinggrowth, non-sporulating growth, or both sporulating and non-sporulatinggrowth of the mixed spore suspension on the surface of the specimenbeing tested when the specimen is tested under the conditions set forthin this paragraph that, at the conclusion of 28 days, cover(s) less than10% of the surface area of the surface of the specimen being tested. Asused in this specification and claims the term “no sporulating growth ornon-sporulating growth” means no observable sporulating growth ornon-sporulating growth of the mixed spore suspension on the surface ofthe specimen being tested at the conclusion of 28 days when the specimenis tested under the conditions set forth in this paragraph.

[0007] To achieve the desired fungi growth resistance, the facing of thesubject invention may include a fungi growth-inhibiting agent. Thefacing also: may include a pesticide; may be modified to provide thefacing with a selected water vapor permeance, e.g. may be perforated toprovide the facing with a selected water vapor permeance, and/or mayinclude a heat activated bonding layer that bonds the facing to theinsulation layer of the assembly. As used in the specification andclaims the term “bonding layer” includes both an adhesive layer thatdoes not require heat activation such as but not limited to a coating,spray on, a spray on fiberized adhesive, or other types of continuous ordiscontinuous adhesive layers, and a heat activated adhesive layer suchas but not limited to asphalt, a polymeric film, a polymeric coating, apolymeric fiber mat, a polymeric fiber mesh, a spray on adhesive, aspray on particulate or fiberized adhesive, or other continuous ordiscontinuous heat activated adhesive layers having a softening pointtemperature sufficiently low to enable the heat activated adhesive layerto be heated to a temperature to effect a bond between the facing and amajor surface of the insulation layer without degrading the facing. Thebonding layer may be pre-applied to the facing or applied to the facingand/or major surface of the insulation layer at the point where thefacing and the insulation layer are being combined.

[0008] The facing may have a central field portion that is sufficientlytransparent to enable the insulation layer of an insulation assembly tobe seen through the facing. The facing may have lateral tabssufficiently transparent to enable framing members to be seen throughthe tabs, sufficiently open to enable wallboard to be directly bonded toframing members overlaid by the tabs, and/or sufficiently greater inintegrity than the field portion of the facing to permit a lessexpensive material to be used for the field portion of the facing. Thefield portion of the facing may include a mineral coating (e.g. claycoating) including modifiers or polymeric coating or film includingmodifiers to stiffen the facing, inhibit fungi growth, treat or controlpests, and/or decrease the flame spread and smoke formationcharacteristics of the facing.

[0009] The facings of the subject invention may be formed from gussetedtubular sheet materials. The facings of the subject invention may beseparable longitudinally at spaced apart locations in the central fieldportions of the facings so that the facings can be applied to pre-cutlongitudinally separable insulation layers and separated where thepre-cut longitudinally separable insulation layers are separable. Thebuilding insulation assemblies of the subject invention may havelaterally compressible resilient insulation layers faced with facingshaving portions, e.g. lateral edge portions, which are or which may beseparated from the insulation layers when the insulation layers arelaterally compressed to form tabs. The building insulation assemblies ofthis paragraph may utilize any of the facing materials of the subjectinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a schematic perspective view of a first embodiment ofthe faced insulation assembly of the subject invention.

[0011]FIG. 2 is a schematic end view of the faced insulation assembly ofFIG. 1.

[0012]FIG. 3 is a schematic view of the circled portion of FIG. 2 on alarger scale than FIG. 2.

[0013]FIGS. 4 and 5 are schematic views of faced insulation assembliesof FIGS. 1 to 3 installed in a wall cavity.

[0014]FIG. 6 is partial schematic view of another embodiment of thefaced insulation assembly of the subject invention showing a tab stripbonded to one of the tabs of the facing of FIGS. 1 to 3.

[0015]FIG. 7 is a schematic transverse cross section though a tubularsheet material with lateral gussets that can be made into a facing ofthe subject invention.

[0016]FIG. 8 is a schematic transverse cross section through the tubularsheet material of FIG. 7 after the tubular sheet material has beencollapsed and bonded together.

[0017] FIGS. 9 to 12 are partial schematic views of embodiments of thefaced insulation assembly of the subject invention showing other tabsthat may be substituted for the tabs shown on the facing of FIGS. 1 to3. The partial schematic views of FIGS. 9 to 12 correspond to the viewof FIG. 3 for the embodiment of FIGS. 1 to 3.

[0018]FIG. 13 is a schematic end view of a faced pre-cut insulationassembly with a facing of the subject invention that is longitudinallyseparable at each location where the insulation layer is longitudinallyseparable.

[0019]FIG. 14 is a schematic end view of a faced pre-cut insulationassembly with a facing of the subject invention that is longitudinallyseparable at each location where the insulation layer is longitudinallyseparable and provided with tabs at each location where the insulationlayer is separable.

[0020]FIG. 15 is schematic view of the circled portion of FIG. 14 on alarger scale than FIG. 14.

[0021]FIG. 16 is a schematic end view of a faced insulation assembly ofthe subject invention where the facing is without preformed tabs.

[0022]FIG. 17 is a schematic view of the circled portion of FIG. 16 on alarger scale than FIG. 16.

[0023]FIG. 18 is a schematic view of a modified version of the circledportion of FIG. 16 on a larger scale than FIG. 16.

[0024]FIG. 19 is a schematic end view of a faced pre-cut insulationassembly with a facing of the subject invention that has no preformedtabs and is longitudinally separable at each location where theinsulation layer is longitudinally separable.

[0025]FIG. 20 is a schematic view of the circled portion of FIG. 19 on alarger scale than FIG. 19.

[0026]FIG. 21 is a schematic view of a modified version of the circledportion of FIG. 19 on a larger scale than FIG. 19.

[0027]FIG. 22 is a schematic view of a reflective insulation made withthe fungi growth resistant kraft paper facings of the subject invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028]FIGS. 1 and 2 show a typical faced insulation assembly 20 of thesubject invention. The faced insulation assembly 20 includes a facing 22of the subject invention and an insulation layer 24. The insulationlayer 24 has first and second major surfaces 26 and 28, which aredefined by the length and width of the insulation layer, and athickness. The facing 22 of the faced insulation assembly 20 is formedof a sheet material that has a central field portion 32 and a pair oflateral tabs 34 that are typically between 0.25 and 1.5 inches in width.The lateral tabs 34 can be unfolded and extended beyond the lateralsurfaces of the insulation layer 24 of the faced insulation assembly 20(typically extended between 0.25 and 1.5 inches beyond the lateralsurfaces of the insulation layer) to overlap the framing members forminga cavity being insulated by the faced insulation assembly and/or forattachment to framing members forming a cavity being insulated by thefaced insulation assembly. The central field portion 32 of the sheet hasa first outer major surface and a second inner major surface. Thecentral field portion 32 of the sheet overlays and is bonded, typicallyby a bonding layer 36 on the inner major surface of central fieldportion 32 of the sheet, to the major surface 26 of the insulation layer24.

[0029]FIGS. 4 and 5 show faced insulation assemblies 20 installed in awall cavity defined on three sides by two spaced apart framing members38 (e.g. wooden 2×4 or 2×6 studs) and a sheet of sheathing 40. As shownin FIG. 4, the tabs 34 of the faced insulation assemblies 20 are securedto the end surfaces of the framing members 38 by staples 42. While theinsulation assemblies 20 are shown installed in wall cavities, theinsulation assemblies 20 may also be installed between framing membersin other building cavities such as but not limited to ceiling, floor,and roof cavities. While, as shown, the tabs 34 are stapled to the endsurfaces of the faming members 38, the tabs may be stapled to the sidesurfaces of the framing members 38, may be bonded to the end surfaces ofthe framing members 38 or the side surfaces of the framing members 38,may overlap end surfaces of the framing members 38 without being securedto the framing members, or, if desired, may be left in their initialfolded configuration.

[0030]FIG. 6 shows a partial cross section of the facing 22 of FIGS. 1to 3 that corresponds to FIG. 3 wherein the lateral tabs 34 include tabstrips 44. The lateral tabs 34 each have a tab strip 44 that overlays,is coextensive or essentially coextensive with, and is bonded to onesurface of the lateral tab 34. The tab strips 44 provide the lateraltabs 34 with increased integrity relative to central field portion 32 ofthe facing sheet 22 for handling and stapling and may be selected tohave sufficient integrity to enable the use of thinner and/or lessexpensive sheet materials for the facing sheet 22. In addition, the tabstrips 44 may also function as release liners overlaying layers orcoatings 46 of pressure-sensitive adhesives on the lateral tabs 34 thatmay be used to secure the lateral tabs 34 to framing members 38.

[0031] While the insulation layers faced with the facings of the subjectinvention may be made of other materials, such as but not limited tofoam insulation materials, preferably, the insulation layers of theinsulation assemblies of the subject invention are resilient fibrousinsulation blankets and, preferably, the faced conventional uncutresilient fibrous insulation blankets and the faced pre-cut resilientfibrous insulation blankets of the subject invention are made ofrandomly oriented, entangled, glass fibers and typically have a densitybetween about 0.3 pounds/ft³ and about 1.6 pounds/ft³. Examples offibers other than glass fibers that may be used with or in place ofglass fibers to form the faced resilient insulation blankets of thesubject invention are mineral fibers, such as but not limited to, rockwool fibers, slag fibers, and basalt fibers; organic fibers such as butnot limited to polypropylene, polyester and other polymeric fibers;natural fibers such as but not limited to cellulose, wood, flax andcotton fibers; and combinations thereof. The fibers in the facedresilient insulation blankets of the subject invention may be bondedtogether at their points of intersection for increased integrity, e.g.by a binder such as but not limited to polycarboxy polymers, polyacrylicacid polymers, urea phenol formaldehyde or other suitable bondingmaterials, or the faced resilient fibrous insulation blankets of thesubject invention may be binder-less provided the blankets possess therequired integrity and resilience.

[0032] While the faced resilient fibrous insulation blankets of thesubject invention may be in roll form (typically in excess of 117 inchesin length), for most applications, such as the insulation of walls inhomes and other residential structures, the faced resilient fibrousinsulation blankets of the subject invention are in the form of battsabout 46 to about 59 inches in length (typically about 48 inches inlength) or 88 to about 117 inches in length (typically about 93 inchesin length). Typically, the widths of the faced resilient fibrousinsulation blankets are substantially equal to or somewhat greater thanstandard cavity width of the cavities to be insulated, for example:about 15 to about 15½ inches in width (a nominal width of 15 inches) fora cavity where the center to center spacing of the wall, floor, ceilingor roof framing members is about 16 inches (the cavity having a width ofabout 142/2 inches); and about 23 to about 23½ inches in width (anominal width of 23 inches) for a cavity where the center to centerspacing of the wall, floor, ceiling or roof framing members is about 24inches (the cavity having a width of about 22½ inches). However, forother applications, the faced resilient fibrous insulation blankets mayhave different initial widths determined by the standard widths of thecavities to be insulated by the insulation blankets.

[0033] The amount of thermal resistance or sound control desired and thedepth of the cavities being insulated by the faced insulation assembliesdetermine the thicknesses of the faced insulation assemblies of thesubject invention, e.g. faced resilient fibrous insulation blankets.Typically, the faced insulation assemblies are about three to about tenor more inches in thickness and approximate the depth of the cavitiesbeing insulated. For example, in a wall cavity defined in part bynominally 2×4 or 2×6 inch studs or framing members, a faced pre-cutresilient fibrous insulation blanket will have a thickness of about 3½inches or about 5½ inches, respectively.

[0034] A first sheet material that may be used for the facing 22 of thefaced insulation assembly 20 and for the facings of the other facedinsulation assemblies of the subject invention is a synthetic paper-likepolymeric film, e.g. an extruded, coextruded, or blown synthetic filledpolyethylene or polypropylene paper film, between 0.5 and 3 mils inthickness. The first sheet material of the subject invention is fungigrowth resistant; preferably exhibits no more than traces of sporulatinggrowth, non-sporulating growth, or both sporulating and non-sporulatinggrowth; and more preferably, exhibits no sporulating or non-sporulatinggrowth. The first sheet material may include a fungi growth-inhibitingagent and preferably, has substantially the same color as the insulationlayer of the faced insulation assembly, e.g. insulation layer 24 of thefaced insulation assembly 20. An example of such a film is a whitepaper-like polymeric film available from Vanguard Plastics, Incorporatedof Dallas, Tex. This film is a 1.25 mil thick film that is coextruded inthree layers with the two surface film layers each being a Papermatch®mineral filled resin film layer about 0.25 mil thick and the middle filmlayer being a clear HDPE resin film layer. Preferably, such a white filmwould be used to face an insulation layer that is white in color such asa white, formaldehyde free, fiberglass insulation. The first sheetmaterial may also have an inner heat activated bonding layer, such asbut not limited to a polymeric film layer, a polymeric coating layer, ora polymeric particulate or fiberized layer, on the inner major surfaceof the first sheet material with a relatively low temperature softeningpoint when compared to the softening point temperature of the otherpolymeric film layer of the sheet material (e.g. a softening pointtemperature that is lower by about 60° F. or more) whereby the innerpolymeric film or coating layer can be used as a heat activated adhesiveto bond the facing to the insulation layer. For example, the innerpolymeric film or coating layer could have a softening point temperatureof 190° F. or less while the other polymeric film layer has a softeningpoint temperature of 250° F. or more

[0035] A second sheet material that may be used for the facing 22 of thefaced insulation assembly 20 and for the facings of the other facedinsulation assemblies of the subject invention is a transparentpolymeric film or a translucent polymeric film. The second sheetmaterial of the subject invention is fungi growth resistant; preferablyexhibits no more than traces of sporulating growth, non-sporulatinggrowth, or both sporulating and non-sporulating growth; and morepreferably, exhibits no sporulating or non-sporulating growth. Thesecond sheet material may include a fungi growth-inhibiting agent and issufficiently clear to enable both the insulation layer of the facedinsulation assembly to be seen through the central field portion of thefacing and the framing members to be seen through the lateral tabs ofthe facing. The ability to see the insulation layer of the insulationassembly through the central field portion of the facing and the framingmembers through the tabs of the facing will enable the installers tomore easily locate the framing members for securing wallboard to theframing members after the tabs of the faced insulation assembly haveoverlapped or overlapped and been secured to end surfaces of the framingmembers. A company logo can be embossed into, printed onto, orwatermarked onto this polymeric film sheet material.

[0036] This second sheet material may be a laminate including two ormore layers of polymeric film that are bonded together and sufficientlyclear to be seen through and enable both the insulation layer of thefaced insulation assembly to be seen through the central field portionof the facing and framing members to be seen through the lateral tabs ofthe facing. Where the second sheet material is a laminate, a companylogo can be watermarked onto the second sheet material by locating thewatermark in the central field portion of the facing on one of theopposed surfaces the two outermost polymeric film layers of thelaminate. Transparent or translucent polymeric films that may be used asthe second sheet materials are polymeric films such as but not limitedto transparent or translucent low density polyethylene films (LDPEfilms), transparent or translucent high density polyethylene films(HDPE), transparent or translucent polypropylene films (PP films) orcombinations thereof. Where the second sheet material is a polymericfilm laminate, the polymeric film layers may be cast or coextruded toform the laminate or heat welded or otherwise bonded together.

[0037] Where the second sheet material is a polymeric film laminate, thesecond sheet material can be strengthened by using stretched polymericfilm layers that are cross-laminated. By a process known as stretching,the polymer chains in a polymeric film layer can be realigned to providethe polymeric film layer with a tear strength in a first direction thatis greater than the initial tear strength of the polymeric film layerand greater than the tear strength of the polymeric film layer in asecond direction perpendicular to the first direction. Two of thesestretched polymeric film layers can be laminated together with the filmsoriented so that the direction of greater tear strength for the firstpolymeric film layer is perpendicular to the direction of greater tearstrength for the second polymeric film layer. The additional tearstrength provided the facing with such a laminate structure will providethe tabs of the facing with greater tear strength for handling and helpprevent staple pull through when the tabs are secured to framing membersby staples.

[0038] While a preferred form of the second sheet material istransparent or translucent, it is also contemplated the one polymericfilm layer or one or more of the polymeric film layers in the laminateforming the second sheet material can be colored. A preferred color fora facing used in a faced insulation assembly with a white insulationlayer, such as a white, formaldehyde free, fiberglass insulation layer,is white. The second sheet material may also have an inner heatactivated bonding layer, such as but not limited to a polymeric film, apolymeric coating layer, or a polymeric particulate or fiberized layer,on the inner major surface of the first sheet material with a relativelylow temperature softening point when compared to the softening pointtemperature of the other polymeric film layer(s) of the sheet material(e.g. a softening point temperature that is lower by about 60° F. ormore) whereby the inner polymeric film or coating layer can be used as aheat activated adhesive to bond the facing to the insulation layer. Forexample, the inner polymeric film or coating layer could have asoftening point temperature of 190° F. or less while the other polymericfilm layer(s) have softening point temperatures of 250° F. or more.Preferably, where the second sheet material is transparent ortranslucent, the heat activated bonding layer would also be sufficientlytransparent or translucent to enable the insulation layer can be seenthrough the facing and bonding layer.

[0039] A third sheet material that may be used for the facing 22 of thefaced insulation assembly 20 and for the facings of the other facedinsulation assemblies of the subject invention is a mineral coated (e.g.clay coated) thin polymeric film laminate with a fungi growth inhibitingagent that may be used rather than a more expensive uncoated polymericfilm. The third sheet material of the subject invention is fungi growthresistant; preferably exhibits no more than traces of sporulatinggrowth, non-sporulating growth, or both sporulating and non-sporulatinggrowth; and more preferably, exhibits no sporulating or non-sporulatinggrowth. The laminate of the third sheet material includes a thin and/orless expensive polymeric film layer, e.g. a polymeric film layer about 1mil or less in thickness, and a mineral coating layer e.g. a claycoating layer. The mineral coating layer forms the outer layer and theouter major surface of the third sheet material. At a relatively lowcost, the mineral coating layer increases the stiffness and body of thethird sheet material, the integrity of the third sheet material, the“cuttability” of the third sheet material, the “cuffability” (ability ofthe third sheet material to hold a fold when forming tabs), and the fireresistance of the third sheet material. The mineral coating can alsoinclude other performance enhancing characteristics to improve theoverall performance of the faced insulation assembly. For example, themineral coating can include a pesticide (e.g. an insecticide, atermiticide), a desired coloration, etc. The mineral coating may bepaint. Polymeric films that may be used in the laminate of the thirdsheet material are polymeric films such as but not limited to lowdensity polyethylene films (LDPE films), high density polyethylene films(HDPE), polypropylene films (PP films), films with substantially thesame performance characteristics as the polyethylene and polypropylenefilms, and/or combinations thereof. The third sheet material may alsohave an inner heat activated bonding layer, such as but not limited to apolymeric film layer, a polymeric coating layer, or a polymericparticulate or fiberized layer, on the inner major surface of the firstsheet material with a relatively low temperature softening point whencompared to the softening point temperature of the other polymeric filmlayer of the sheet material (e.g. a softening point temperature that islower by about 60° F. or more) whereby the inner polymeric film orcoating layer can be used as a heat activated adhesive to bond thefacing to the insulation layer. For example, the inner polymeric film orcoating layer could have a softening point temperature of 190° F. orless while the other polymeric film layer has softening pointtemperatures of 250° F. or more.

[0040] A fourth sheet material that may be used for the facing 22 of thefaced insulation assembly 20 and for the other facings of the facedinsulation assemblies of the subject invention is a mineral coated thinlightweight kraft paper laminate (e.g. a clay coated 20-30 or 30-40lbs/3 MSF kraft paper laminate) that may be used rather than a 35-38lbs/3 MSF extensible natural kraft commonly used to face fiberglassinsulation assemblies. The fourth sheet material of the subjectinvention is fungi growth resistant; preferably exhibits no more thantraces of sporulating growth, non-sporulating growth, or bothsporulating and non-sporulating growth; and more preferably, exhibits nosporulating or non-sporulating growth. The laminate of the fourth sheetmaterial includes a lightweight and less expensive kraft paper layer, amineral coating layer (e.g. clay coating layer) and a fungigrowth-inhibiting agent. The mineral coating layer forms the outer layerand the outer major surface of the fourth sheet material. At arelatively low cost, the mineral coating layer increases the stiffnessand body of the fourth sheet material, the integrity of the fourth sheetmaterial, the “cuttability” of the fourth sheet material, the“cuffability” (ability of the fourth sheet material to hold a fold whenforming tabs), and the fire resistance of the fourth sheet material. Themineral coating can also provide the facing with other performanceenhancing characteristics to improve the overall performance of thefaced insulation assemblies of the subject invention. For example, themineral coating can include a pesticide (e.g. an insecticide, atermiticide), a desired coloration, etc. The mineral coating may bepaint. The fourth sheet material may also have an inner heat activatedbonding layer, such as but not limited to a polymeric film layer, apolymeric coating layer, or a polymeric particulate or fiberized layer,on the inner major surface of the lightweight kraft paper layer with alow temperature softening point, e.g. a softening point of less than225° F. whereby the inner polymeric film or coating layer can be used asa heat activated adhesive to bond the facing to the insulation layer.

[0041] A fifth sheet material that may be used for the facing 22 of thefaced insulation assembly 20 and for the other facings of the facedinsulation assemblies of the subject invention is a laminate including anatural kraft paper or tissue paper overlaid on each major surface witha polymeric coating or film layer. The fifth sheet material of thesubject invention is fungi growth resistant; preferably exhibits no morethan traces of sporulating growth, non-sporulating growth, or bothsporulating and non-sporulating growth; and more preferably, exhibits nosporulating or non-sporulating growth. The polymeric coating or filmlayers encapsulate the natural kraft paper or tissue paper and therebymake the sheet material more moisture resistant and fungi growthresistant than a typical uncoated kraft facing material. An example of apolymeric coating or film layer is a polyolefin coating or film layer,such as but not limited to a polyethylene or polypropylene coating orfilm layer with a fungi growth-inhibiting agent. An example of the fifthsheet material is a laminate that includes an unbleached natural kraftbase layer, e.g. a 20-30 lb/3 msf natural kraft that is encapsulatedbetween outer and inner white-pigmented HDPE film layers such as HDPEfilm layers applied at a weight of about 7-15 lbs/3 msf. This example ofthe fifth sheet material is a balanced sheet material that protects theencapsulated kraft layer, has excellent fold-ability (folds easily andholds the fold), is almost waterproof, and exhibits increased toughness.The polymeric coating or film layer forming the outer layer of thelaminate and the outer major surface of the laminate may have a highertemperature softening point than the polymeric coating or film layerforming the inner layer of the laminate and the inner major surface ofthe laminate e.g. the outer polymeric layer may have a softening pointof about 250° F. while the inner polymeric layer may have a softeningpoint of less than 190° F. (a 60° F. temperature difference). The innerlayer of the laminate can thus be used as a heat activated bonding layerfor bonding the facing to the first major surface of the insulationlayer. The outer polymeric layer can be made is various colors. Apreferred color for a facing used in a faced insulation assembly with awhite insulation layer, such as a white, formaldehyde free, fiberglassinsulation layer, is white.

[0042] A sixth sheet material that may be used for the facing 22 of thefaced insulation assembly 20 and for the other facings of the facedinsulation assemblies of the subject invention is a lightweight nonwovenpolymeric filament or fiber mat (e.g. a lightweight spunbond nonwovencontinuous polyester, polypropylene or polyethylene filament mat or alightweight nonwoven staple polyester, polypropylene or polyethylenefiber mat) or a lightweight nonwoven fiberglass mat. The sixth sheetmaterial of the subject invention is fungi growth resistant; preferablyexhibits no more than traces of sporulating growth, non-sporulatinggrowth, or both sporulating and non-sporulating growth; and morepreferably, exhibits no sporulating or non-sporulating growth. Anexample of a lightweight spunbond nonwoven polymeric filament mat thatmay be used as the sixth sheet material is a lightweight spunbondnonwoven continuous polyester filament mat having a weight between 15and 30 grams per square meter, such as a spunbond nonwoven polyester matsold by Johns Manville International, Inc., under the designation type488/15, type 488/20, or type 488/30. An example of a lightweightnonwoven fiberglass mat that may be used as the sixth sheet material isa lightweight nonwoven fiberglass mat having a weight between 20 and 80grams per square meter, such as a nonwoven fiberglass mat sold by JohnsManville International, Inc., under the trade designation Dura-Glass®style 3011 mat. These mats typically have a water vapor permeance ratinggreater than 5 perms. A filament web bonding layer, an open mesh bondinglayer, or a sprayed on particulate or fiberized bonding layer made of apolymeric material having a lower softening point than the mat may beadhered to an inner major surface of either of these mats and used as aheat activated bonding layer to bond either of these mats to the firstmajor surface of the insulation layer. For example a polypropylene webor open mesh having a softening point of about 250° F. or less can beadhered to the inner major surface of a spunbond nonwoven polyester mathaving a softening point of about 350° F. or greater.

[0043] A seventh sheet material that may be used for the facing 22 ofthe faced insulation assembly 20 and for the facings of the other facedinsulation assemblies of the subject invention is a laminate thatincludes a lightweight nonwoven polymeric filament or fiber mat (e.g. alightweight spunbond nonwoven continuous polyester, polypropylene orpolyethylene filament mat or a lightweight nonwoven staple polyester,polypropylene or polyethylene fiber mat) or a lightweight nonwovenfiberglass mat overlaid with a polymeric film or polymeric coatinglayer. The seventh sheet material includes a fungi growth-inhibitingagent. The seventh sheet material of the subject invention is fungigrowth resistant; preferably exhibits no more than traces of sporulatinggrowth, non-sporulating growth, or both sporulating and non-sporulatinggrowth; and more preferably, exhibits no sporulating or non-sporulatinggrowth. An example of a lightweight spunbond nonwoven polymeric filamentmat that may be used as the seventh sheet material is a lightweightspunbond nonwoven continuous polyester filament mat having a weightbetween 15 and 30 grams per square meter, such as a spunbond nonwovenpolyester mat sold by Johns Manville International, Inc., under thetrade designation type 488/15, type 488/20, or type 488/30. An exampleof a lightweight nonwoven fiberglass mat that may be used as the seventhsheet material is a lightweight nonwoven fiberglass mat having a weightbetween 20 and 40 grams per square meter, such as a nonwoven fiberglassmat sold by Johns Manville International, Inc., under the tradedesignation Dura-Glass® style 3011 mat. These mats typically have awater vapor permeance rating greater than 5 perms. The polymeric film orpolymeric coating layer forms the outer layer and the outer majorsurface of the seventh sheet material and when combined with thespunbond nonwoven polymeric mat or fiberglass mat can provide theseventh sheet material with a water vapor permeance rating equal to orless than 1 perm. A filament web bonding layer, a mesh bonding layer, ora particulate or fiberized bonding layer made a polymeric materialhaving a lower softening point than the mat may be adhered to an innermajor surface of either of these mats and used as a heat activatedbonding layer to bond either of these mats to the first major surface ofthe insulation layer. For example a polypropylene web, open mesh, orfiber layer having a softening point of about 250° F. or less can beadhered to the inner major surface of a spunbond nonwoven polyester mathaving a softening point of about 350° F. or greater.

[0044] An eighth sheet material that may be used for the facing 22 ofthe faced insulation assembly 20 and for the other facings of the otherfaced insulation assemblies of the subject invention is a collapsedtubular sheet material that includes first and second lateral gussetportions. The eighth sheet material of the subject invention is fungigrowth resistant; preferably exhibits no more than traces of sporulatinggrowth, non-sporulating growth, or both sporulating and non-sporulatinggrowth; and more preferably, exhibits no sporulating or non-sporulatinggrowth. Depending on which of the first seven sheet materials is used toform the eighth sheet material, the eighth sheet material may or may notinclude a fungi growth-inhibiting agent. As shown in FIGS. 7 and 8,which show the tubular sheet material 48 prior to and after the sheethas been collapsed to form the facing, the tubular sheet material hasfirst and second central portions 50 and 52 extending between andjoining the two lateral gusset portions 54 and 56. The central portions50 and 52 of the collapsed tubular sheet material are bonded together toform the central field portion of the facing sheet. As shown the lateralgusset portions 54 and 56 each include four layers while the centralportion of the collapsed tubular sheet material includes two layers. Byincluding an additional lateral gusset or gussets, the lateral gussetportions could each include six or more layers. The inclusion ofadditional layers in each of the lateral gusset portions 54 and 56 ofthe collapsed tubular sheet material relative to the central portion ofthe collapsed tubular sheet material enables the formation of lateraltabs on the facing of increased integrity and tear through resistancewhile using a thinner or less expensive sheet material to form collapsedtubular sheet material. The collapsed tubular sheet material 48 maybemade from transparent, translucent or pigmented polymeric films of oneor more layers (e.g. cast or coextruded films) such as but not limitedto LDPE films, HDPE films, PP films or combinations thereof with orwithout an outer mineral coating or polymeric coating layer or fromkraft paper or lightweight natural kraft paper with or without an outermineral coating or polymeric coating layer or a polymeric film layer.

[0045] As previously indicated each facing material of the subjectinvention is fungi growth resistant; preferably exhibits no more thantraces of sporulating growth, non-sporulating growth, or bothsporulating and non-sporulating growth and more preferably, exhibits nosporulating or non-sporulating growth. Where the sheet material used toform the facing is a multilayer sheet material and includes a fungigrowth-inhibiting agent and/or pesticide, the fungi growth-inhibitingagent or fungi growth-inhibiting agent and pesticide may be included inany one or more or all of the layers in the sheet material, especiallythe outermost layer, mixed throughout the layer(s), or appliedtopically. Where the sheet material includes at least one polymeric filmor polymeric coating layer, the fungi growth-inhibiting agent or fungigrowth-inhibiting agent and pesticide may be included in any one or moreof the polymeric film or polymeric coating layers. Where the sheetmaterial includes one or more kraft or tissue paper layers, the fungigrowth inhibiting agent or fungi growth inhibiting agent and pesticidemay be included in any one or more of the kraft or tissue paper layers.Where the sheet material includes one or more mineral coating, polymericcoating, or ink coating layers, the fungi growth-inhibiting agent orfungi growth-inhibiting agent and pesticide may be included in any oneor more of the coating layers. Where the sheet material includes one ormore nonwoven polymeric mat layers, the fungi growth-inhibiting agent orfungi growth-inhibiting agent and pesticide may be included in any oneor more of the polymeric mat layers.

[0046] As alternatives to only including the fungi growth-inhibitingagent or fungi growth-inhibiting agent and pesticide in the sheetmaterial of the facing, the fungi growth-inhibiting agent or fungigrowth-inhibiting agent and pesticide could be: included only in thebonding layer bonding the central field portion of the facing to thefirst major surface of the insulation layer or included in both thesheet material of the facing and the bonding layer bonding the centralfield portion of the facing to the first major surface of the insulationlayer.

[0047] An example of a fungi growth-inhibiting agent is the fungi growthresistance additive 2-(4-Thiazolyl) Benzimidazole, also known as “TBZ”.Multiple forms of TBZ are available for specific applications inpolymers, adhesives, coatings and additives. One example of the fungigrowth resistance additive is available from Ciba Specialty Chemicalsunder the trade designation Irgaguard F-3000 fungi growth resistanceadditive. It is believed that the inclusion of the, Irgaguard F-3000fungi growth resistance additive in amounts between 0.05% and 0.5% byweight of the materials in the polymeric films, polymeric coatings,mineral coatings, ink coatings, kraft or tissue papers, and continuouspolymeric filaments of the first through the eighth sheet material willeffectively inhibit fungi growth. Examples of other antimicrobial,biocide fungi growth-inhibiting agents that may be used are silverzeolyte fungi growth inhibiting agents sold by Rohm & Haas Company underthe trade designation KATHON fungi growth-inhibiting agent, by AngusChemical Company under the trade designation AMICAL 48 fungigrowth-inhibiting agent, and by Healthshield Technologies, LLC. underthe trade designation HEALTHSHIELD fungi growth-inhibiting agent.

[0048] An example of one type of pesticide that may be used in thesubject invention is a termiticide that contains fipronil as the activeingredient. This termiticide is non-repellent to termites and lethal totermites through ingestion, contact and/or transferal. AventisEnvironmental Science USA of Montvale, N.J. sells such a termiticideunder the trade designation “TERMIDOR”. Since the termites do not smell,see or feel this termiticide, the termites continue to pass freelythrough the treated area picking up the termiticide and carrying thetermiticide back to the colony nest. In the colony nest, other termitesthat contact the contaminated termites through feeding or grooming orthrough cannibalizing the termites killed by the termiticide becomecarriers of the termiticide thereby spreading the termiticide throughoutthe colony and exterminating the termites.

[0049] Preferably, each of the faced insulation assemblies of thesubject invention has a composite flame spread and smoke developedrating equal to or less than 25/50 as measured by the ASTM E 84-01tunnel test method, entitled “Standard Test Method for Surface BurningCharacteristics of Building Materials”, published July 2001, by ASTMInternational of West Conshohocken, Pa. Each sheet material of thesubject invention and each facing of the subject invention, as bonded tothe insulation layer, passes the ASTM fungi test C 1338-00, entitled“Standard Test Method for Determining Fungi Resistance of InsulationMaterials and Facings”, published August 2000, by ASTM International ofWest Conshohocken, Pa. Preferably each sheet material of the subjectinvention and each facing of the subject invention, as bonded to theinsulation layer, has a rating of 1 or less and more preferably 0, asrated by the ASTM fungi test G 21-96 (Reapproved 2002), entitled“Standard Practice for determining Resistance of Synthetic PolymericMaterials to Fungi”, published September 1996 by ASTM International ofWest Conshohocken, Pa.

[0050] For certain applications, it is preferable to have the sheetmaterial of the subject invention and the field portion of the facing ofthe subject invention, as bonded to the major surface of the insulationlayer (e.g. major surface 26 of the insulation layer 24), exhibit awater vapor permeance rating of less than 1 grain/ft²/hour/inch Hg (lessthan 1 perm) so that the facing functions as a vapor retarder or barrierfor the faced fibrous insulation blanket, e.g. a faced resilientfiberglass insulation blanket. For other applications, it is preferableto have the sheet material of the subject invention “water vaporbreathable” and the field portion of the facing of the subjectinvention, as bonded to the major surface of the insulation layer (e.g.major surface 26 of insulation layer 24) “water vapor breathable” andexhibit a water vapor permeance rating of more than 1grain/ft²/hour/inch Hg (more than 1 perm); preferably, about 3 or moregrain/ft²/hour/inch Hg (about 3 or more perms); and, more preferably,about 5 or more grains/ft²/hour/inch Hg (about 5 or more perms) so thatthe facing functions as a porous facing for the faced insulationassembly that permits the passage of water vapor through the facedsurface of the faced insulation assembly of the subject invention. Forsheet materials such as the first through the fifth, the seventh and theeighth sheet materials that normally have a water vapor permeance ratingequal to or less than one perm, the sheet material forming the centralfield portion of the facing (field portion 32 in the facing 22) can beselectively modified (e.g. perforated) to increase the water vaporpermeance rating to a desired level. If the sheet materials areperforated, the perforations may be either microscopic-perforations ormacroscopic-perforations with the number and the size of theperforations per unit area of the central field portion of the facingbeing selected to achieve the desired water vapor permeance rating forthe facing. In addition, the bonding layer bonding the central fieldportion of the facing to the first major surface of the insulation layercan be applied so that the facing as applied to the insulation layerprovides the faced insulation assembly with the desired water vaporpermeance rating. For example, the bonding layer applied to the centralfield portion of the facing could be formed in: a series of spaced apartlongitudinally extending adhesive strips of selected width(s) andspacing(s), a series of spaced apart transversely extending adhesivestrips of selected width(s) and spacing(s), a uniform or random patternof adhesive dots of selected size(s) and spacing(s), a continuousadhesive layer of a selected uniform thickness or selected varyingthicknesses, or some combination of the above, to achieve with the watervapor permeance rating of the central field portion of the facing aselected water vapor permeance rating for the central field portion ofthe facing as applied to the first major surface of the insulationlayer. With the sixth sheet material, which may have a water vaporpermeance rating of 25, 50, 100 greater, or any sheet material that mayhave a higher water vapor permeance rating than desired for a particularapplication, the bonding layer could be used to reduce the water vaporpermeance rating of the central field portion of the facing without theuse of an outer coating on the sheet material.

[0051] As discussed above, various bonding agents may be used as thebonding layer to bond the sheet material forming the central fieldportion of the facings of the subject invention to the major surface ofthe insulation layer, such as but not limited to amorphouspolypropylene, and these bonding agents may be applied by differentmethods. For example, as the faced insulation assembly is beingmanufactured, the bonding agent could be applied to the inner majorsurface of the facing immediately prior to applying the facing to theinsulation layer by: printing the bonding agent on the inner majorsurface of the facing, applying the bonding agent to the inner majorsurface of the facing using a particulate or fiberized hot melt spray orwater based spray, or by applying a water based or other bonding agentto the inner major surface of the facing by roll coating. Alternatively,the bonding agent, e.g. a heat activated bonding agent, can bepreapplied to the inner major surface of the facing using the samemethods when the facing is manufactured and rolled into long rolls andthe bonding agent can be activated when the rolls of facing are unwoundand adhered to the major surface of the insulation layer.

[0052] FIGS. 9 to 22 show additional embodiments of the faced insulationassembly of the subject invention. The elements of the faced insulationassemblies of FIGS. 9 to 22 that correspond to those of FIGS. 1 to 3will have corresponding reference numerals in the hundreds with the samelast two digits as the reference numerals used for those elements inFIGS. 1 to 3. Unless otherwise stated the elements of FIGS. 9 to 22identified with reference numerals having the same last two digits asthe reference numerals referring to those elements in FIGS. 1 to 3 areand function the same as those of FIGS. 1-3.

[0053]FIG. 9 shows a partial cross section of a faced insulationassembly 120 of the subject invention with a facing sheet 122 that hasZ-folded tabs 158 (only one of which is shown) and FIG. 10 shows apartial cross section of a faced insulation assembly 220 with of thesubject invention that has C-folded tabs 260 (only one of which isshown) that can be unfolded and extended beyond the lateral surface ofthe insulation layer 124 or 224 for attachment to and/or to overlayframing members. The Z-folded tabs 158 and C-folded tabs 260 aresubstituted for the tabs 34, are typically between about 0.5 and about2.0 inches in width, and typically can be extended beyond the lateralsurfaces of the insulation layers 124 and 224 between about 0.25 andabout 1.5 inches. Like the central field portion 32 and lateral tabs 34of facing 22, the central field portion 132 and lateral tabs 158 offacing 122 and the central field portion 232 the lateral tabs 260 of thefacing 222 are made from the same piece of sheet material.

[0054]FIGS. 11 and 12 show partial cross sections of additionalembodiments 320 and 420 of the faced insulation assembly of the subjectinvention. In the facings 322 and 422 of the embodiments 320 and 420,lateral tabs 364 and 466 are substituted for the lateral tabs 34 offacing 22. The tabs 364 and 466 are made of materials that differ fromthe material used to form the central field portions 332 and 432 of thefacings 322 and 422; are bonded by adhesive layers 368 and 470, by ultrasonic welding or by other bonding means to the upper surface of lateraledge portions of the central field portion 332 and 432 of the facings322 and 422; and are typically between about 0.5 and about 2.0 inches inwidth. The tab 364 of the faced insulation assembly 320 is like the tab34 of the faced insulation assembly 20. The tab 466 of the facedinsulation assembly 420 of FIG. 12 is a Z-folded tab. The tabs 364 and466 can be unfolded and extended beyond the lateral surfaces of theinsulation layers 324 and 424 (typically extended between 0.25 and 1.5inches beyond the lateral surfaces of the insulation layers) forattachment to or to overlay framing members. By way of example, thematerials used to form the central field portions 332 and 432 of thefacings 322 and 422 and the lateral tabs 364 and 466 of the facings 332and 432 may differ in thickness (e.g. a 1.0 mil thick films form thecentral field portions 332 and 432 of the facings while a 1.5 mil thickfilms form the tabs 364 and 466) and/or in composition (e.g. the centralfield portions 332 and 432 of the facings may be made from polypropylenefilms while the tabs 364 and 466 are formed from polyester films). Thecentral field portions 332 and 432 of the facings may be made of singlelayers while the tabs 364 and 466 are each a laminate of multiple layersfor greater integrity. The central field portions 332 and 432 of thefacings may be made of laminates containing a certain number of layerswhile the tabs 364 and 466 are made of laminates containing a differentnumber of layers and typically more layers for increased tab integrity.The layers of the laminates may include both layers of sheet materials(e.g. film, mat, or paper materials) and coating materials. The centralfield portions of the facings each may have one or more layers of afilm, a coated film, paper, a coated paper, a fiberglass or spunbondpolymeric filament or fiber mat, or a coated fiberglass or spunbondpolymeric filament or fiber mat while the tabs are made of an openspunbond polymeric filament or fiber mat or an open mesh that issufficiently open to permit adhesive to pass through the tabs to bondwallboard directly to framing members through the tabs.

[0055]FIG. 13 shows an embodiment 520 of the faced insulation assemblyof the subject invention wherein both the facing 522 and the insulationlayer 524 are longitudinally separable to form faced insulation sections572 having lesser widths than the faced insulation assembly 520. Theinsulation layer 524 has one or more longitudinally extending series ofcuts and separable connectors, schematically represented by lines 574,which enable the insulation layer 524 to be pulled apart or separated byhand into the insulation sections 572 of lesser widths than theinsulation layer 524. For each such series of cuts and separableconnectors 574 in the insulation layer 524, the field portion 532 of thesheet 530 forming the facing 522 has a line of weakness 576 therein thatis longitudinally aligned with the series of cuts and separableconnectors so that the facing can also be separated or pulled apart byhand at each series of cuts and separable connectors. The line ofweakness 576 may be formed as a perforated line, as an etched score linethat reduces the thickness of the sheet material along the line, or theline may be otherwise weakened to facilitate the separation of thefacing sheet by hand along the line 576. Other than the one or moreseries of cuts and separable connectors 574 in the insulation layer 524and the one or more lines of weakness 576 in the facing 522, the facedinsulation assembly 520 of FIG. 13 is the same as the faced insulationassembly 20.

[0056]FIGS. 14 and 15 show an embodiment 620 of the faced insulationassembly of the subject invention wherein both the facing 622 and theinsulation layer 624 are longitudinally separable to form facedinsulation sections 678 having lesser widths than the faced insulationassembly 624. The insulation layer 624 has one or more longitudinallyextending series of cuts and separable connectors, schematicallyrepresented by lines 680, which enable the insulation layer 624 to bepulled apart or separated by hand into the insulation sections 678 oflesser widths than the insulation layer 624. For each such series ofcuts and separable connectors 678 in the insulation layer 624, the fieldportion 632 of the sheet 630 forming the facing 622 has a fold 682therein that is longitudinally aligned with the series of cuts andseparable connectors. A separable pressure sensitive or other separablebonding adhesive 684 separably bonds the two segments of each fold 682to each other and, typically, the fold line 686 joining the segments ofeach fold 682 will be perforated, scored, or otherwise weakened topermit the fold to be pulled apart or separated by hand at the fold line686 to form tab segments. Preferably, each segment of each fold 682 isbetween about 0.25 and about 1.5 inches in width. Other than the one ormore series of cuts and separable connectors 680 in the insulation layer624 and the one or more folds 682 in the facing 622 with weakened foldlines 686, the faced insulation assembly 620 of FIGS. 14 and 15 is thesame as the faced insulation assembly 20.

[0057]FIGS. 16, 17 and 18 show a faced insulation assembly 720 of thesubject invention that is faced with a facing 722 of the subjectinvention without preformed tabs. The faced insulation assembly 720 ofFIGS. 16, 17 and 18 includes the facing 722 and an insulation layer 724.The insulation layer 724 is made of a resilient insulation material,such as but not limited to a fiberglass insulation, that can becompressed in the direction of its width, e.g. laterally compressed aninch or more, and, after the compressive forces are released, willrecover or substantially recover to its initial width. The insulationlayer 724 has first and second major surfaces 726 and 728, which aredefined by the length and width of the insulation layer, and athickness. The facing 722 of the faced insulation assembly 720 is formedby a sheet material that has a central field portion 732, that issubstantially coextensive with the first major surface of the insulationlayer 724, but has no preformed tabs. The central field portion 732 ofthe facing 722 has a first outer major surface and a second inner majorsurface. The central field portion 732 of the facing 722 overlays and isbonded, typically by a bonding layer 736 on the inner major surface ofcentral field portion 732 of the facing, to the major surface 726 of theinsulation layer 724. When the insulation layer 724 is compressed in thedirection of its width to fit between a pair of framing members that arespaced a distance less than the width of the faced insulation assembly720, the lateral edge portions 788 of the sheet 730 separate or can beseparated from the major surface 726 of the insulation layer andextended beyond the lateral surfaces of the laterally compressedinsulation layer 724 (between 0.25 and about 1.5 inches) to provide, ifdesired, a vapor retarding barrier between the facing and the framingmembers and/or for attachment to the framing members. As best shown inFIG. 17, in a preferred form of this embodiment the bonding layer 736bonding the central field portion 732 of the facing to the first majorsurface 726 of the insulation layer 724 does not extend to the lateraledges of either the insulation layer 724 or the facing 722 so that thelateral edge portions 788 of the facing 722 are not directly bonded tothe major surface 726 of the insulation layer. This facilitates theseparation of the lateral edge portions 788 of the facing 722 from theinsulation layer 724 when the insulation layer is compressed laterallyso that the lateral edge portions 788 of the facing 722 can extendbeyond the lateral surfaces of the laterally compressed insulation layer724 to form lateral tabs. However, as shown in FIG. 18, the bondinglayer 736 bonding the central field portion 732 of the facing 722 to thefirst major surface 726 of the insulation layer 724 may extend to thelateral edges of the insulation layer 724 and the facing 722 so that thebond between the lateral edge portions 788 of the facing 722 and themajor surface 726 of the insulation layer must be broken before thelateral edge portions 788 of the facing 722 can be separated from themajor surface 726 of the insulation layer 724 and extended to form thelateral tabs.

[0058]FIGS. 19, 20 and 21 show an embodiment 820 of the faced insulationassembly of the subject invention wherein both the facing 822 and theinsulation layer 824 are longitudinally separable to form facedinsulation sections 890 having lesser widths than the faced insulationassembly 820. Like the faced insulation assembly 720 of FIGS. 16, 17 and18, the facing of faced insulation assembly 820 does not have preformedtabs and the insulation layer 824 is made of a resilient insulationmaterial, such as but not limited to a fiberglass insulation, that canbe compressed in the direction of its width, e.g. laterally compressedan inch or more, and, after the compressive forces are released, willrecover or substantially recover to its initial width. The insulationlayer 824 has one or more longitudinally extending series of cuts andseparable connectors, schematically represented by lines 892, whichenable the insulation layer 824 to be pulled apart or separated by handinto the insulation sections 890 of lesser widths than the insulationlayer 824. For each such series of cuts and separable connectors 892 inthe insulation layer 824, the field portion 832 of the sheet 830 formingthe facing 822 has a line of weakness 894 therein that is longitudinallyaligned with the series of cuts and separable connectors and can bepulled apart or separated by hand. The line of weakness 894 may beformed as a perforated line, as an etched score line that reduces thethickness of the sheet material along the line, or the line may beotherwise weakened to facilitate the separation of the facing sheetalong the line 894.

[0059] Preferably, as shown in FIG. 19, the bonding layer 836 bondingthe central field portion 832 of the facing sheet to the first majorsurface 826 of the insulation layer 824 does not extend to the lateraledges of either the insulation layer 824 or the facing 822 so that thelateral edge portions 896 of the facing sheet are not directly bonded tothe major surface 826 of the insulation layer. Preferably, the bondinglayer 836 will end from about 0.25 to about 1.5 inch from the lateraledges of the facing sheet 822 and the insulation layer 824 so that thewidth of the unbonded lateral edge portions 896 is between about 0.25and about 1.5 inches. Preferably, as shown in FIGS. 19 and 20, thebonding layer bonding the central field portion 832 of the facing sheetto the first major surface 826 of the insulation layer 824 is alsoomitted from portions 898 of the facing located adjacent each series ofcuts and separable connectors 892 in the insulation layer 824 so thatthe facing is not directly bonded to the insulation layer along eachseries of cuts and separable connectors 892. Preferably, the bondinglayer 836 will be omitted for a spacing of about 0.25 to about 1.5inches from each side of each series of cuts and separable connectors inthe insulation layer 824 and the lines 894 of weakness in the facingsheet 822 so that the widths of the unbonded facing portions 898 arebetween about 0.25 and about 1.5 inches. The omission of bonding agentfrom adjacent the lateral edges of the faced insulation assembly 820facilitates the separation of the lateral edge portions 896 of thefacing sheet from the insulation layer 824 so that the lateral edgeportions 896 of the facing 822 can be extended as tabs beyond thelateral surfaces of the laterally compressed insulation layer 824 orextended as tabs beyond the lateral surfaces of compressed insulationsections 890 that have been separated from the insulation layer 824. Theomission of bonding agent from adjacent the cuts and separableconnectors 892 facilitates the separation of the portions 898 of thefacing sheet from the insulation layer 824 adjacent each series of cutsand separable connectors 892 so that the portions 898 of the facingsheet can be extended as tabs beyond the lateral surfaces of thelaterally compressed insulation sections 890. However, the bonding layer836 bonding the central field portion 832 of the facing to the firstmajor surface 826 of the insulation layer 824 may extend to the lateraledges of the insulation layer 824 and the facing sheet (e.g. as shown inFIG. 18) so that the lateral edge portions 896 of the facing sheet mustbe separated from the major surface 826 of the insulation layer 824 toform the lateral tabs and, as shown in FIG. 21, the facing may bedirectly bonded to the major surface 826 of insulation layer 824adjacent each series of cuts and separable connectors 892 so that theportions 898 of the facing sheet must be separated from the majorsurface 826 of the insulation layer 824 to form tabs.

[0060] When the insulation layer 824 of faced insulation assembly 820 iscompressed in the direction of its width to fit between a pair offraming members that are spaced a distance less than the width ofinsulation layer 824, the lateral edge portions 896 of the facing sheetseparate or can be separated from the major surface 826 of theinsulation layer and extended as tabs beyond the lateral surfaces of thelaterally compressed insulation layer 824 to provide, if desired, avapor retarding barrier between the facing and the framing membersand/or for attachment to the framing members. When an insulation section890 of faced insulation assembly 820 is compressed in the direction ofits width to fit between a pair of framing members that are spaced adistance less than the width of insulation section 890, the portions ofthe facing sheet adjacent the lateral surfaces of the compressedinsulation section 890 (portions 896 and/or 898) separate or can beseparated from the major surface 826 of the insulation layer andextended as tabs beyond the lateral surfaces of the laterally compressedinsulation section 890 to provide a vapor retarding barrier between thefacing and the framing members and/or for attachment to the framingmembers.

[0061]FIG. 22 shows an embodiment 920 of the faced insulation assemblyof the subject invention. The faced insulation assembly 920 includes afacing 922 of the subject invention and a reflective sheet layer 912that radiates heat, e.g. a foil sheet material or a metallized film orother metallized sheet material. The facing 922 of the faced insulationassembly 920 is formed of a sheet material that has a central fieldportion 932 extending between a pair of lateral edge portions 933 thatare typically between 0.25 and 1.5 inches in width. The reflective sheetlayer 912 has a central field portion 914 extending between a pair oflateral edge portions 916 that are typically between 0.25 and 1.5 inchesin width. The central field portion 932 of the facing 922 and thecentral field portion 914 of the reflective sheet layer 912 are spacedfrom each other (e.g. spaced from each other about ⅜ of an inch) to forman insulating air space between the central field portion 932 of thefacing 922 and the central field portion 914 of the reflective layer912. The first major surface of the central field portion 914 of thereflective sheet layer 912, which opposes the central field portion 932of the facing 920, is reflective. The second major surface of thecentral field portion 914 of the reflective sheet layer 912 may also bereflective. In addition, there may be a spacer or spacers (e.g.paperboard spacers not shown) between the central field portion 932 ofthe facing 920 and the central field portion 914 of the reflective sheet912 to assure that a spacing is maintained between the central fieldportion of the facing and the central field portion of the reflectivesheet. The lateral edge portions 933 of the facing 922 and the lateraledge portions 916 of the reflective sheet layer 912 are bonded togetherto form the lateral tabs 934 of the faced insulation assembly 920 thatextend laterally beyond the insulating portion of the faced insulationassembly, e.g. to overlap framing members (e.g. furring strips 938 orother framing members) forming a cavity being insulated by the facedinsulation assembly and/or for attachment to framing members forming acavity being insulated by the faced insulation assembly.

[0062] In describing the invention, certain embodiments have been usedto illustrate the invention and the practices thereof. However, theinvention is not limited to these specific embodiments as otherembodiments and modifications within the spirit of the invention willreadily occur to those skilled in the art on reading this specification.Thus, the invention is not intended to be limited to the specificembodiments disclosed, but is to be limited only by the claims appendedhereto.

What is claimed is:
 1. A faced building insulation assembly, comprising:an insulation layer; the insulation layer having a length, a width and athickness; the insulation layer having first and second major surfacesdefined by the length and width of the layer; and a facing comprising asheet having a central field portion overlaying and substantiallycoextensive with the first major surface of the insulation layer; thecentral field portion of the sheet having a first outer major surfaceand a second inner major surface bonded to the first major surface ofthe insulation layer; the central field portion of the sheet being fungigrowth resistant; and the facing, as bonded to the insulation layer,being fungi growth resistant.
 2. The faced building insulation assemblyaccording to claim 1, wherein: the central field portion of the sheetexhibits no more than traces of sporulating growth, non-sporulatinggrowth, or both sporulating and non-sporulating growth; and the facing,as bonded to the insulation layer, exhibits no more than traces ofsporulating growth, non-sporulating growth, or both sporulating andnon-sporulating growth.
 3. The faced building insulation assemblyaccording to claim 1, wherein: the central field portion of the sheetexhibits no sporulating or non-sporulating growth; and the facing, asbonded to the insulation layer, exhibits no sporulating growth ornon-sporulating growth.
 4. The faced building insulation assemblyaccording to claim 1, wherein: the sheet has first and second lateraltabs extending for the length of the sheet that are separated from eachother by the central field portion of the sheet.
 5. The faced buildinginsulation assembly according to claim 4, wherein: the insulation layeris separable longitudinally by hand at a location spaced inwardly fromlateral edge surfaces of the insulation layer; and the sheet has alongitudinally extending fold in the central field portion of the sheetthat extends for the length of the sheet, is spaced inwardly from eachof the lateral tabs, and is aligned longitudinally with the separablelocation in the insulation layer; and the fold comprises first andsecond tab segments separably joined together along a fold line that isweakened to facilitate separation by hand of the tab segments.
 6. Thefaced building insulation assembly according to claim 1, wherein: theinsulation layer is resilient; the insulation layer is separablelongitudinally by hand at a location spaced inwardly from lateral edgesurfaces of the insulation layer; and the sheet has a longitudinallyextending line of weakness in the central field portion of the sheetthat extends for the length of the sheet, is spaced inwardly from eachlateral edge of the sheet, is aligned longitudinally with the separablelocation in the insulation layer, and is separable by hand.
 7. The facedbuilding insulation assembly according to claim 1, wherein: the sheetconsists essentially of a synthetic paper-like polymeric film layerbetween about 0.5 and about 3 mils in thickness.
 8. The faced buildinginsulation assembly according to claim 7, wherein: the syntheticpaper-like polymeric film layer contains the fungi growth-inhibitingagent; and the central field portion of the sheet is bonded to the firstmajor surface of the insulating layer by a heat activated bonding layer.9. The faced building insulation assembly according to claim 1, wherein:the sheet comprises a polymeric film layer; the sheet is sufficientlyclear to enable the first major surface of the insulation layer to beseen through the central field portion of the sheet and is bonded to theinsulation layer so that the first major surface of the insulation layercan be seen through the central field portion of the sheet.
 10. Thefaced building insulation assembly according to claim 9, wherein: afungi growth-inhibiting agent is contained within the polymeric filmlayer of the sheet; and the central field portion of the sheet is bondedto the first major surface of the insulating layer by a heat activatedbonding layer.
 11. The faced building insulation assembly according toclaim 1, wherein: the sheet consists essentially of an outer mineralcoating layer and an intermediate polymeric film layer between about 1mil or less in thickness; and the sheet includes a fungigrowth-inhibiting agent.
 12. The faced building insulation assemblyaccording to claim 11, wherein: the central field portion of the sheetis bonded to the first major surface of the insulation layer by a heatactivated bonding layer.
 13. The faced building insulation assemblyaccording to claim 11, wherein: the fungi growth-inhibiting agent iscontained within the outer mineral coating layer of the sheet.
 14. Thefaced building insulation assembly according to claim 1, wherein: thesheet consists essentially of an outer mineral coating layer and aninner lightweight 20 to 40 lbs/3 MSF kraft paper layer; and the sheetincludes a fungi growth-inhibiting agent.
 15. The faced buildinginsulation assembly according to claim 14, wherein: the central fieldportion of the sheet is bonded to the first major surface of theinsulation layer by a heat activated bonding layer.
 16. The facedbuilding insulation assembly according to claim 1, wherein: the sheetconsists essentially of an outer polymeric film or coating layer and aninner lightweight natural kraft paper layer; the sheet includes a fungigrowth-inhibiting agent; the central field portion of the sheet isbonded to the first major surface of the insulation layer by a heatactivated bonding layer that is a polymeric film or coating layer; andthe outer polymeric film or coating layer and the heat activated bondinglayer encapsulate the natural kraft paper layer.
 17. The faced buildinginsulation assembly according to claim 16, wherein: the fungigrowth-inhibiting agent is contained within the outer polymeric film orcoating layer of the sheet.
 18. The faced building insulation assemblyaccording to claim 1, wherein: the sheet consists essentially of a matlayer; and the central field portion of the sheet is bonded to the firstmajor surface of the insulation layer by a heat activated bonding layer.19. The faced building insulation assembly according to claim 18,wherein: the mat layer is a spunbond nonwoven continuous polymericfilament mat weighing between about 15 and about 30 grams per squaremeter.
 20. The faced building insulation assembly according to claim 18,wherein: the mat layer is a nonwoven fiberglass mat weighing betweenabout 20 and about 80 grams per square meter.
 21. The faced buildinginsulation assembly according to claim 1, wherein: the sheet consistsessentially of an outer polymeric film or coating layer and an inner matlayer; the sheet includes a fungi-growth inhibiting agent; and thecentral field portion of the sheet is bonded to the first major surfaceof the insulation layer by a heat activated bonding layer.
 22. The facedbuilding insulation assembly according to claim 21, wherein: the matlayer is a spunbond nonwoven continuous polymeric filament mat weighingbetween about 15 and about 30 grams per square meter.
 23. The facedbuilding insulation assembly according to claim 1, wherein: the sheetcomprises a laminate formed from a collapsed tubular sheet; the tubularsheet having first and second lateral gusset portions; the tubular sheethaving first and second central portions extending between and joiningthe lateral gusset portions; each of the lateral gusset portions havingat least four layers bonded together to form lateral tabs on the sheet;and the first and second central portions of the tubular sheet beingbonded together to form the central field portion of the sheet.
 24. Thefaced building insulation assembly according to claim 1, wherein: thesheet includes a pesticide; and the faced insulation assembly has aflame spread and smoke developed rating equal to or less than 25/50 asmeasured by the ASTM E 84-01 tunnel test method.
 25. The faced buildinginsulation assembly, according to claim 1, wherein: the insulation layeris resilient; and the first major surface of the insulation layer haslateral edge portions extending inward from and along lateral edges ofthe first major surface; and the sheet has lateral edge portionsoverlaying the lateral edge portions of the first major surface of theinsulation layer; the central field portion of the sheet extends betweenthe lateral edge portions of the sheet; and the lateral edge portions ofthe sheet are not bonded to the lateral edge portions of the insulationlayer whereby when the insulation layer is compressed laterally, thelateral edge portions of the facing sheet extend beyond the lateraledges of the first major surface of the insulation layer to form tabs.26. A facing for a faced building insulation assembly, comprising: asheet having a length and a width; the sheet having a central fieldportion for overlaying and being bonded to a major surface of aninsulation layer; the central field portion of the sheet having a firstouter major surface and a second inner major surface for bonding to amajor surface of an insulation layer overlaid by the sheet; and thesheet being fungi growth resistant.
 27. The facing for a faced buildinginsulation assembly according to claim 26, wherein: the sheet exhibitsno more than traces of sporulating growth, non-sporulating growth, orboth sporulating and non-sporulating growth.
 28. The facing for a facedbuilding insulation assembly according to claim 26, wherein: the sheetexhibits no sporulating growth or non-sporulating growth.
 29. The facingfor a faced building insulation assembly according to claim 26, wherein:the sheet has first and second lateral tabs extending for the length ofthe sheet that are separated from each other by the central fieldportion of the sheet.
 30. The facing for a faced building insulationassembly according to claim 26, wherein: the sheet has first and secondlateral tabs extending for the length of the sheet that are separatedfrom each other by the central field portion of the sheet; and the sheethas at least one longitudinally extending fold in the central fieldportion of the sheet that extends for the length of the sheet and isspaced inwardly from each of the lateral tabs; and the fold comprisesfirst and second tab segments separably joined together along a foldline that is weakened to facilitate separation by hand of the tabsegments.
 31. The facing for a faced building insulation assemblyaccording to claim 26, wherein: the central field portion of the sheetis a laminate; and a heat activated bonding layer forms the second innermajor surface of the sheet.
 32. The facing for a faced buildinginsulation assembly according to claim 31, wherein: the sheet consistsessentially of an outer synthetic paper-like polymeric film layerbetween about 0.5 and about 3 mils in thickness and the heat activatedbonding layer.
 33. The facing for a faced building insulation assemblyaccording to claim 32, wherein: a fungi growth-inhibiting agent iscontained within the outer synthetic paper-like polymeric film layer ofthe sheet.
 34. The facing for a faced building insulation assemblyaccording to claim 31, wherein: the sheet comprises an outer polymericfilm layer between about 0.5 and about 3 mils in thickness and the heatactivated bonding layer; and the sheet is sufficiently clear to enablean insulation layer faced with the facing to be seen through the centralfield portion of the sheet.
 35. The facing for a faced buildinginsulation assembly according to claim 34, wherein: a fungigrowth-inhibiting agent is contained within the outer polymeric filmlayer of the sheet.
 36. The facing for a faced building insulationassembly according to claim 31, wherein: the sheet consists essentiallyof an outer mineral coating layer, an intermediate polymeric film layerbetween about 1 mil or less in thickness, the heat activated bondinglayer, and a fungi growth-inhibiting agent.
 37. The facing for a facedbuilding insulation assembly according to claim 36, wherein: the fungigrowth-inhibiting agent is contained within the outer mineral coatinglayer of the sheet.
 38. The facing for a faced building insulationassembly according to claim 31, wherein: the sheet consists essentiallyof an outer mineral coating layer, an intermediate lightweight 20 to 40lbs/3 MSF kraft paper layer, the heat activated bonding layer, and afungi growth-inhibiting agent.
 39. The facing for a faced buildinginsulation assembly according to claim 38, wherein: the fungigrowth-inhibiting agent is contained within the outer mineral coatinglayer of the sheet.
 40. The facing for a faced building insulationassembly according to claim 31, wherein: the sheet consists essentiallyof an outer polymeric film or coating layer, an intermediate lightweightnatural kraft paper layer, the heat activated bonding layer, and a fungigrowth-inhibiting agent; the heat activated bonding layer is a polymericfilm or coating layer; and the outer polymeric film or coating layer andthe heat activated bonding layer encapsulate the natural kraft paperlayer.
 41. The facing for a faced building insulation assembly accordingto claim 40, wherein: the fungi growth-inhibiting agent is containedwithin the outer polymeric film or coating layer of the sheet.
 42. Thefacing for a faced building insulation assembly according to claim 31,wherein: the sheet consists essentially of an outer mat layer and theheat activated bonding layer.
 43. The facing for a faced buildinginsulation assembly according to claim 42, wherein: the mat layer is aspunbond nonwoven continuous polymeric filament mat weighing betweenabout 15 and about 30 grams per square meter.
 44. The facing for a facedbuilding insulation assembly according to claim 42, wherein: the matlayer is a nonwoven fiberglass mat weighing between about 20 and about80 grams per square meter.
 45. The facing for a faced buildinginsulation assembly according to claim 31, wherein: the sheet consistsessentially of an outer polymeric film or coating layer, an intermediatemat layer, the heat activated bonding layer, and a fungi-growthinhibiting agent.
 46. The facing for a faced building insulationassembly according to claim 45, wherein: the mat layer is a spunbondnonwoven polymeric filament mat weighing between about 15 and about 30grams per square meter.
 47. The facing for a faced building insulationassembly according to claim 45, wherein: the mat layer is a nonwovenfiberglass mat weighing between about 20 and about 80 grams per squaremeter.
 48. The facing for a faced building insulation assembly accordingto claim 26, wherein: the sheet comprises a laminate formed from acollapsed tubular sheet; the tubular sheet having first and secondlateral gusset portions; each of the lateral gusset portions having atleast four layers bonded together to form lateral tabs on the sheet; thetubular sheet having first and second central portions extending betweenand joining the lateral gusset portions; and the first and secondcentral portions of the tubular sheet being bonded together to form thecentral field portion of the sheet; and a heat activated bonding layeron the central field portion of the sheet forms the second inner majorsurface of the sheet.
 49. The facing for a faced building insulationassembly according to claim 26, wherein: the sheet includes a pesticide.50. The facing for a faced building insulation assembly according toclaim 26, wherein: the central field portion of the sheet has a watervapor permeance rating greater than 1 perm.
 51. A faced buildinginsulation assembly, comprising: a facing comprising sheet; the facingsheet having lateral edge portions and a central field portion extendingbetween the lateral edge portions of the facing sheet; the facing sheetbeing fungi growth resistant; a reflective sheet material; thereflective sheet material having lateral edge portions and a centralfield portion extending between the lateral edge portions of thereflective sheet material; and the lateral edge portions of the facingsheet being bonded to the lateral edge portions of the reflective sheetmaterial; and the central field portion of the facing sheet being spacedfrom the central field portion of the reflective sheet material to forman insulating space within the faced insulation assembly.
 52. The facedbuilding insulation assembly according to claim 51, wherein: the facingsheet exhibits no more than traces of sporulating growth,non-sporulating growth, or both sporulating and non-sporulating growth.53. The faced building insulation assembly according to claim 51,wherein: the facing sheet exhibits no sporulating or non-sporulatinggrowth.
 54. The faced building insulation assembly according to claim51, wherein: the fungi growth resistant sheet material includes apesticide.
 55. The faced building insulation assembly according to claim51, wherein: the central field portion of the facing sheet has a watervapor permeance rating of about 5 perms or greater.